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A study on the detection of misalignment between piercing punch and die using a bolt-type piezo sensor  

Jeon, Yong-Jun (Mold & Metal Forming R&D Department, Korea Institute of Industrial Technology)
Kim, Dong-Earn (Mold & Metal Forming R&D Department, Korea Institute of Industrial Technology)
Publication Information
Design & Manufacturing / v.15, no.4, 2021 , pp. 51-56 More about this Journal
Abstract
Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.
Keywords
Alignment; Eccentricity; Piercing; PiezoBolt; Sensor;
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